Integrated photovoltaic roofing component and panel

ABSTRACT

A combination roofing panel and solar module includes a flexible membrane sheet, such as a single-ply membrane sheet, and a plurality of elongated solar or photovoltaic modules arranged side-by-side, end-to-end, or adjacent each other. The modules are adhered to the flexible membrane, and the edges of the modules having electrical connectors or electrodes are arranged to face each other or be aligned with each other. The electrical connectors are connected by a solder connection to module electrodes through apertures in a bottom surface of the flexible membrane and are connected in series. The series electrical connectors are connected directly to direct current (DC) electric devices, to a combiner box, to another panel or to an inverter which provides coverts direct current (DC) to alternating current electricity for use in residential, commercial or industrial building structures. The ends and elongated edges of a roofing component or panel having the flexible membrane and modules can be sealed for protection.

CROSS REFERENCE TO RELATED APPLICATION(S)

This application is a continuation of application Ser. No. 10/351,299filed Jan. 23, 2003, the disclosure of which is incorporated fullyherein by reference.

FIELD OF THE INVENTION

The present invention relates to roofing components, panels and systems,and more particularly, to a photovoltaic roofing component and panelhaving solar or photovoltaic modules integrated with a flexible membraneto protect a building from environmental elements while also generatingelectricity.

DESCRIPTION OF RELATED ART

Various types of roofing materials have been utilized to providebuilding structures protection from the sun, rain, snow and otherweather and environment elements. Examples of known roofing materialsinclude clay tiles, cedar and composition shingles and metal panels, andBUR materials, (e.g., both hot and cold applied bituminous basedadhesives, emulsions and felts), which can be applied to roofingsubstrates such as wood, concrete and steel. Additionally, single-plymembrane materials, e.g., modified bitumen sheets, thermoplastics suchas polyvinylchloride (PVC) or ethylene interpolymer, vulcanizedelastomers, e.g., ethyl propylene diene (monomer) terpolymer (EPDM) andNeoprene, and non-vulcanized elastomers, such as chlorinatedpolyethylene, have also been utilized as roofing materials.

While such roofing materials may be satisfactory for the basic purposeof protecting a building structure from environmental elements, theiruse is essentially limited to these protective functions.

Solar energy has received increasing attention as an alternativerenewable, non-polluting energy source to produce electricity as asubstitute to other non-renewable energy resources, such as coal and oilthat also generate pollution. Some building structures have beenoutfitted with solar panels on their flat or pitched rooftops to obtainelectricity generated from the sun. These “add-on” can be installed onany type of roofing system as “stand alone” solar systems. However, suchsystems typically require separate support structures that are boltedtogether to form an array of larger solar panels. Further, the “add-on”solar panels are heavy and are more costly to manufacture, install andmaintain. For example, the assembly of the arrays is typically doneon-site or in the field rather than in a factory. Mounting arrays ontothe roof may also require structural upgrades to the building.Additionally, multiple penetrations of the roof membrane can compromisethe water-tight homogeneity of the roof system, thereby requiringadditional maintenance and cost. These “add-on” solar panel systems mayalso be considered unsightly or an eyesore since they are attached toand extend from a roof. These shortcomings provide a barrier to morebuilding structures being outfitted with solar energy systems which, inturn, increase the dependence upon traditional and more limited andpolluting energy resources.

Other known systems have combined roofing materials and photovoltaicsolar cells to form a “combination” roofing material which is applied tothe roof of the building structure. For example, one known systemincludes a combination of a reinforced single-ply membrane and a patternof photovoltaic solar cells. The solar cells are laminated to themembrane and encapsulated in a potting material. A cover layer isapplied to the combination for protection. The solar cells areinterconnected by conductors, i.e., conductors connect each row inseries, with the inner rows being connected to the outer rows by busbars at one end, and with the other ends terminating in parallelconnection bars.

However, known combinations of roofing materials having solar cells canbe improved. For example, known combinations of solar cells and roofingtypically require multiple internal and external electricalinterconnections to be performed on site in order to properly connectall of the solar modules. As a result, substantial wiring, connectorsand related hardware are needed to properly wire all of the individualsolar cells. Such wiring is typically performed by an electrician ratherthan a roofer, thereby increasing labor costs and complicating theinstallation. Additional wire and connection components can also resultin composite roofing panels requiring excessive field handling andweight, thereby making storage, transportation, and installation ofpanels more difficult and expensive. Further, a multitude ofinterconnections must typically be completed before an installer can runmultiple wires or connection lines to an electrical device, a combinerbox or an inverter. Finally, increasing the number of wires andinterconnections in a panel to be installed under field conditionsincreases the likelihood that the electrical connection in the panelwill be broken, e.g., by variables associated with constructive fieldconditions or wire connections being exposed to inclement weather and/orother hazards (rodents, pigeons, etc.)

A need, therefore, exists for an integrated photovoltaic roofingcomponent and panel that reduces the need for separate installers tohandle roofing materials and solar and related electrical components.The component and panel should also be conveniently stored andtransported, and utilize a more efficient wiring system to simplify theinstallation of photovoltaic roofing components and panels, therebyreducing the maintenance and operational costs of the system.

SUMMARY OF THE INVENTION

The present invention provides an improved integrated solar orphotovoltaic roofing component and panel that can be attached to aroofing surface. The improved component and panel includes a flexiblemembrane sheet and a plurality of elongated solar or photovoltaicmodules. The plurality of elongated photovoltaic modules is attached toa top surface of the flexible membrane sheet. Each module is arrangedside-by-side or end to end such that the electrical leads are located atadjacent ends of the modules. Thus, the wiring ends can be aligned withor adjacent to each other to form the integrated photovoltaic roofingcomponent or panel.

In further accordance with the invention, the electricalinterconnections between individual solar cells of a solar module arecompleted before the plurality of solar modules are adhered to theflexible membrane. As a result, the installer is not required to connectpositive and negative electrodes of each individual solar cell, therebyreducing the electrical interconnections between all the solar cells andmodules. Thus, the integrated photovoltaic roofing panel can be unrolledonto a roof of a building structure and installed and properly connectedwith fewer electrical components and connections than conventionalcombination photovoltaic systems.

Also in accordance with the present invention, as the cells arepreassembled into modules, the edges of the elongated solar modules areencapsulated with a sealant.

According to a further aspect of the present invention, a “panel”includes about two to twelve elongated photovoltaic modules. A panel caninclude two modules with wiring ends facing each other, or pairs ofmodules can be arranged in two sub-panels of about one to six modules.The sub-panels are arranged such that the wiring ends of the module(s)are in close proximity to each other on the flexible membrane.Electrodes are mounted in the wiring ends, thereby providing a centrallocation having all of the electrodes to be accessed. Each solar moduleincludes a positive electrode and a negative electrode.

The electrodes can be accessed through apertures defined by aperturescut into in the flexible membrane. Solder sections are inserted throughthe apertures and connected to the module electrodes. The set ofelectrodes of the modules may then be connected in a combination ofseries and parallel connections to complete the wiring of the panel. Thewiring series combines into a plug or other connector. The wires,electrodes and solder sections are hermetically sealed within theflexible membrane (utilizing adhesive, hot-air welding or radiofrequency welding), and the plug is handily available for connection toanother photovoltaic roof panel to form a larger array or system or toan inverter or current converter.

BRIEF DESCRIPTION OF THE DRAWINGS

Referring now to the drawings in which like reference numbers representcorresponding parts throughout:

FIGS. 1A-D illustrate various integrated roofing componentconfigurations having two modules and six modules;

FIG. 2A illustrates an integrated roofing panel having two groups of sixmodules arranged side-by-side, and FIG. 2B illustrates an alternativepanel configuration with two groups of three modules;

FIGS. 3A-B illustrate the manner in which an integrated photovoltaicroofing component or panel can be applied to a flat and pitched rooftopof a building structure;

FIG. 4 is a cross-section view of an integrated photovoltaic roofingcomponent or panel according to the present invention;

FIG. 5 is a cross-section view of an exemplary photovoltaic module;

FIG. 6 is a cross-section view of the exemplary photovoltaic module ofFIG. 5 that is laminated or adhered to a flexible membrane to form anintegrated roofing component or panel;

FIGS. 7A-C are respective top, bottom and exploded views of moduleelectrodes;

FIG. 8 is an exploded view of an edge of a module showing the electrodesin further detail and apertures formed through a flexible membrane;

FIG. 9 is a top view of an integrated photovoltaic roofing panel havingtwo groups of six modules arranged side by side and facing each otherwith electrodes connected in series;

FIG. 10 is a cross-section view of the electrodes located beneath themembrane and insulation layers of a photovoltaic integrated component orpanel;

FIG. 11 illustrates a system including an integrated photovoltaicroofing panel according to the present invention and an inverter forgenerating alternating current electricity; and

FIG. 12 is a flow diagram of the process of manufacturing an integratedphotovoltaic roofing component or panel according to the presentinvention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The present invention provides a combination roofing component andpanel. The component and panel include a plurality of solar orphotovoltaic modules (“PV modules”) attached to a flexible membranesheet, such as a single-ply membrane. The modules are arranged adjacenteach other, e.g., side-by-side or end-to-end. The ends of the moduleshave electrical connectors or electrodes that are arranged to face eachother or are adjacent or aligned with each other. The electricalconnectors extend from internal module electrodes of the solar modulesand can extend through apertures formed in a bottom surface of theflexible membrane. The electrical connectors conduct direct current (DC)electricity that may be connected directly to DC electrical devices orconnected to an inverter that provides alternating current (AC)electricity to residential, commercial or industrial buildingstructures. Additionally, the AC electricity can also be reverse meteredinto a utility grid. The ends and sides of the elongated edges of the PVmodule of a roofing component or panel can be sealed for protection.

Protective outer layers can also be applied over the electricalconnectors and on the flexible membrane to hermetically seal theapertures that are used to access the internal module electrodes alongwith the copper wiring utilized to string the individual modules in aseries leaving a “quick-connect” plug readily available to connect withthe next PV roofing component or panel.

As a result, the wiring of modules is simplified, and the amount of timerequired to install photovoltaic roofing panels is reduced since most ofthe wiring connections are made prior to field installation andencapsulated within a central area, thus minimizing the number of fieldconnections required to connect individual components or panels.

Having generally described some of the features of the presentinvention, in the following description, reference is made to theaccompanying drawings which form a part hereof and which show by way ofillustration specific embodiments in which the invention may bepracticed. It is to be understood that other embodiments may be utilizedas structural changes may be made without departing from the scope ofthe present invention.

Referring to FIGS. 1A-C, one embodiment of the present inventionprovides an integrated photovoltaic roofing component 100. One exemplaryintegrated photovoltaic roofing component 100 includes a plurality ofelongated photovoltaic or solar modules 110 and 111 (generally module110). Each module 110 is a collection of solar cells, e.g., cells 110a-v and 111 a-v (generally solar cell 110 a). A solar cell 110 a is thesmallest photoactive unit of a solar module 110. The exemplary modules110 shown in FIGS. 1A-C include twenty-two (22) photovoltaic cells 110a, but other numbers of solar cells 110 a can be utilized.

Each solar module 110 has a first elongated side 130, a second elongatedside 132, a front or head or electrode end 134, a rear or butt end 136,a top surface 138, and a bottom surface 139 (not visible in top view ofFIG. 1). The bottom surfaces 139 of the modules 110 are bonded, adheredor laminated to a top surface 142 of a flexible membrane 140. A bottomsurface 144 (not visible in top view) of the flexible membrane 140, oranother layer that is attached to the bottom surface 144, is attached,either partially or fully, to a roofing surface of the buildingstructure such as a roof, wall, canopy, or another building structure.

The modules 110 are arranged such that one end of the modules 110, i.e.,the ends having electrical connectors, e.g., soldering pads or wire orcopper tape leads 170 and 171 (generally connectors 170) are adjacenteach other. Each connector 170 includes a negative lead 170 a and apositive lead 170 b that are connected with adjacent module electrodes.The electrical connections can be in series or in parallel. However, forpurposes of explanation and illustration, this specification refers toseries connections. For example, in FIG. 1A, the electrode sides 130 and132 of modules 110 and 111 are side by side and adjacent each other. InFIG. 1B, the modules 110 and 111 are adjacent each other and staggeredor offset such that the electrode ends 134 are near or adjacent eachother. In FIG. 1C, the electrode ends 134 are adjacent and face eachother. As shown in FIGS. 1A-C, the electrode ends 134 with theelectrical connectors or wire ends 170 are contained within a common orcentral area 160.

With these exemplary configurations, the time required to connect eachphotovoltaic module 110 is reduced since the module electrodes 170 canbe connected by, for example, soldering, within the central area 160.Thus, the present invention reduces the amount of work performed byelectricianse.

Persons of ordinary skill in the art will recognize that the exemplaryroofing components 100 shown in FIGS. 1A-C can include different numbersof modules 110 having different numbers of solar cells 110 a and can bearranged in various configurations [and that the exemplary component 100configurations shown are merely illustrative of these otherconfigurations]. For example, as shown in FIG. 10D, an exemplary roofingcomponent 100 includes six modules 110-115 arranged side-by-side suchthat the wire connectors 170 are located at the same end 134 and areadjacent each other in the central area 160.

Referring to FIG. 2A, the components 100 shown in FIGS. 1A-D can be usedto form an integrated photovoltaic panel 200. An exemplary panel 200includes two groups of modules 210 and 212 (generally “group 210”), eachgroup having six modules. Specifically, modules 110-115 are arrangedside-by-side in the first group 210, and modules 116-121 are arrangedside-by-side in the second group 212. In this exemplary panel 200, themodules 110 of each group are arranged so that the electrode or leadingends 134 are adjacent and face each other. For example, the electrodeends 134 of modules 110 and 121 face each other, and the electrode ends134 of modules 111 and 120 face each other. As a result, the electrodeends 134 with the electrical connectors 170-181 (generally 170) arealigned and the positive and negative leads 170 b and 171 a of modules110 and 111 respectively can be connected in series within the centralarea 160. Inter-module connections (in this “daisy-chain” example: 170b-171 a, 171 b-172 a, . . . 180 b-181 a) within the central area 160 arecompleted in a manufacturing facility prior to field installation thusreducing time and complexity required during on site.

For purposes of explanation and illustration, FIG. 2A shows anintegrated photovoltaic roofing panel 200 having twelve modules 110 intwo groups 210 and 212, each group having six modules 110. However, manypanel 200, module 110, cell 110 a and group configurations can beutilized what was in plant. An integrated photovoltaic roofing panel 200can include different numbers of modules 110 depending on the dimensionsof a roofing surface to be covered. For example, as shown in FIG. 2B, apanel 200 includes two groups 210 and 212, in which the modules areadjacent each other and arranged in a staggered configuration. Eachgroup has three modules 110-115 with electrode pairs 170-175. Further, apanel 200 can include modules 110 having different numbers of solarcells 110 a (FIG. 1 illustrates twenty-two solar cells 110 a in anexemplary module 110). Thus, the present invention is flexible andadaptable to satisfy the needs and dimensions of a building structure orsize of an underlying flexible membrane 140.

FIGS. 3A-B show an integrated roofing panel 200 applied to a rooftop ofa building structure for purposes of protection from the environment, aswell as producing electricity. Specifically, FIG. 3A illustrates anintegrated photovoltaic panel 200 with modules 110-121 attached to aflexible membrane sheet 140. The membrane sheet 140 is applied to theroofing surface 300 of a building structure 310. The exemplary panel 200covers a portion of the flat roof surface 300, but the remainder of theroof 300 can be similarly covered by other panels 200 or smallercomponents 100 as needed. Similarly, FIG. 3B illustrates a panel 200with modules 110-121 attached to a flexible membrane sheet 140 that isapplied to a pitched or angled roof surface 320 of a building structure330. The remainder of the roof 320 can also be similarly covered.

Persons of ordinary skill in the art will recognize that more than onepanel 200 or component 100 can be installed on a rooftop or otherbuilding surface or structure depending on the size of the surface anddesired solar capabilities. Further, the panels 200 can have differentnumbers and sizes of solar modules 110 and flexible membrane sheets 140.For purposes of illustration, this specification generally refers tomodules attached to a single membrane sheet, but various sizes andnumbers of flexible membrane sheets can be used. Thus, the integratedphotovoltaic panel 200 and component 100 of the present invention areefficient, effective and flexible photovoltaic roofing materials withsimplified wiring.

FIGS. 4-12 illustrate various aspects of an integrated photovoltaiccomponent 100 and panel 200, electrical connections, a systemincorporating a component 100 or panel 200, and a method ofmanufacturing a component or panel. While the following descriptiongenerally refers to a photovoltaic roofing “panel”, persons of ordinaryskill in the art will recognize that the description also applies to anintegrated photovoltaic roofing component 100 or a combination of one ormore components and panels.

FIG. 4 shows a general cross-section of an integrated photovoltaicroofing panel 200 of the present invention. An exemplary solar module110 or 111 (generally 110) that is adhered to the flexible membrane 140can be solar module model no. PVL-128 or a UNI-SOLAR® PVL solar module,available from Bekaert ECD Solar Systems, LLC, 3800 Lapeer Road, AuburnHills, Mich. This specific exemplary solar module 110 is adhered to thetop surface 142 of the flexible membrane 140 with an adhesive 400. Oneexemplary adhesive 400 that can be used to bond or laminate the bottomsurface 139 of the module 110 to the top surface 142 of the flexiblemembrane 140 is a reactive polyurethane hot-melt QR4663, available fromHenkel Henkel KGaA, Kenkelstrasse 67, 40191 Duesseldorf, Germany.

One exemplary flexible membrane sheet 140 that can be used is asingle-ply membrane, e.g., an EnergySmart® S327 Roof Membrane, availablefrom Sarnafil, Inc., Roofing and Waterproofing Systems, 100 Dan Road,Canton, Mass. Persons of ordinary skill in the art will recognize thatwhile one exemplary flexible membrane 140 is selected for purposes ofexplanation and illustration, many other flexible membranes andsingle-ply membranes can be utilized. For example, alternativesingle-ply membranes 140 that can be used include modified bitumenswhich are composite sheets consisting of bitumen, modifiers (APP, SBS)and/or reinforcement such as plastic film, polyester mats, fiberglass,felt or fabrics, vulcanized elastomers or thermosets such as ethylpropylene diene (monomer) terpolymer (EPDM) and non-vulcanizedelastomers such as chlorinated polyethylene, chlorosulfonatedpolyethylene, polyisobutylene, acrylonitrite butadiene polymer.

The module 110 includes negative and positive internal electrodesoldering pads 170 a(−) and 170 b(+), respectively. Insulating tape 492is applied to soldering pad 170 a. Apertures 450 a and 450 b are formedthrough the flexible membrane 140, adhesive 400 and a lower portion ofthe module 110, to access the internal module soldering pads 170 a and170 b. Solder connections or sections 470 a and 470 b are formed withinthe apertures 450 a and 450 b. The module 111 includes a similararrangement of negative and positive electrode soldering pads 171 a(−)and 171 b(+), apertures 451 a and 451 b, and solder sections 471 a and471 b. Insulating tape 493 b is applied to soldering pad 411 a.

The solder sections 470 a and 470 b provide an electrical connectionbetween the internal module soldering pads 170 a and 170 b andrespective inter-module wire connection leads 430 and 431. As a result,the internal module negative electrode 170 a, solder section 470 a, andconnection electrode 430 provide a electrical circuit with the terminusof wire 430 ending in a quick-connect plug (not shown in FIG. 4). Theinternal positive module electrode 170 b, solder section 470 b, andinter-module connection lead 431 provide an electrical circuitconnecting in series to the adjacent internal negative module electrode171 a through solder section 471 a. In this series wiring example, thepattern of wiring positive to negative between adjacent modules iscontinued until all additional module electrodes are “daisy-chained” tocomplete the series circuit. The final positive internal moduleconnection to electrode 181 b (+) (see FIG. 2) terminates the serieswiring with connection to a quick-connect plug (not shown in FIG. 4)similar to termination to wire 430.

If necessary, one or more insulative layers 490 can be applied to thebottom surface 144 of the flexible membrane 140 and over the connectionelectrodes 430 and 431 and additional module electrodes in theelectrical path for protection and support. The insulative layer 490 canbe applied by an adhesive layer 480.

An edge sealant 495 can be applied to the edges of modules 110 and 111.More specifically, an edge sealant 495 can be applied to seal or coverany gaps or an edge between an adhesive layer 400 and the bottomsurfaces of modules 110 and 111, as well as an edge between the adhesivelayer 400 and the top surface 142 of the membrane 140.

Panels 200 having the general configuration shown in FIG. 4 can berolled up for storage and transportation. For example, typical rolls ofa flexible membrane 140 can have a width as large as about 10 feet and alength cut and rolled to between about 30 or 100 feet. Modules 110 canbe applied to the flexible membrane 140 and cut to various dimensions asneeded, and are then unrolled and applied to a rooftop.

FIG. 5 shows a cross-section of a solar module 110 that is generallyrepresentative of the exemplary solar module 110 model no. PVL-128 or aUNI-SOLAR® PVL solar module, available from Bekaert ECD Solar Systems,LLC, 3800 Lapeer Road, Auburn Hills, Mich. This particular solar module110 includes twenty-two solar cells 110 a (as illustrated in FIGS. 1 and2A-B).

This particular exemplary solar module 110 includes a top Tefzel layer500 having a thickness of about two (2) mil (1 mil=0.001 inch), a firstethylene-propylene rubber (EVA) layer 510 having a thickness of about 26mil beneath the Tefzel layer 500, a fiberglass layer 520 having athickness of about 15-20 mil beneath the EVA layer 510, a photoreactiveor solar cell layer 530 having a thickness of about 5 mil beneath thefiberglass layer 520, a second EVA layer 540 having a thickness of about8 mil beneath the photoreactive layer 530, and a Tedlar layer 550 havinga thickness of about 2-5 mil beneath the second EVA layer 540. FIG. 5also shows the negative internal electrode 170 a and the positiveinternal electrode 170 b mounted within the second EVA layer 540 of themodule 110. The negative internal electrode 170 a is insulated from thephotoreactive layer 530 by an insulation strip or layer 492 to prevent ashort circuit.

The exemplary solar module 110 model no. PVL-128, as manufactured,typically includes a factory bonding adhesive 560 (shown as dotted line)on the underside of the module laminate, i.e., applied to the undersideof the Tedlar layer 550. However, for purposes of attaching orlaminating the solar module 110 to the top surface 142 of the flexiblemembrane 140 in the present invention, this factory adhesive 560 can bereplaced by the hot melt adhesive 300 mentioned earlier or an adhesiveapplied using another adhesion process.

FIG. 6 illustrates a cross-section of an integrated photovoltaic roofingpanel 200 in which the module 110 (with components illustrated in FIG.5) is laminated or adhered to the top surface 142 of the flexiblemembrane 140. Specifically, apertures 450 a and 450 b are formed throughthe membrane sheet 140, adhesive 400, and the bottom surface orunderside of the module, i.e., through the Tedlar layer 550 andpartially through the second EVA layer 540 to access the internalelectrodes 410 a and 410 b within the second EVA layer 540. FIG. 6 alsoshows edge seals 495 applied over the membrane layer 140, and to theadhesive 400, and module 110.

After the solder sections 470 a and 470 b are applied to the internalmodule electrodes 170 a and 170 b through the apertures 450 a and 450 b,and the connection electrodes 430 and 431 are connected to respectivesolder sections 470 a and 470 b, a second adhesive layer 480 can beapplied to the bottom surface 144 of the membrane 140. Additionally, aninsulative membrane layer 490 can be applied to the bottom of theadhesive 480 (or to the bottom surface 144 of the membrane 140 if theadhesive 480 is not utilized). The insulative layer 490 insulates andencapsulates the connection electrodes 430 and 431 and additional moduleelectrodes in the electrical path. An exemplary membrane layer 490 thatcan be used is 48 mil S327, available from Sarnafil 100 Dan Road,Canton, Mass.

The bottom surface of the panel 200, is applied to the roofing surfaceor substrate (e.g., roof sections 300, 320 in FIG. 3) or other buildingstructure surface. Thus, when the panels 200 are to be installed, thepanel roll can be unrolled onto the rooftop and attached thereto usingvarious known techniques (e.g., various adhesives utilized to adhere theflexible PV panel to the substrate or mechanical attachment utilizingscrews and plates, combined with hot air welding, solvent welding orradio frequency (RF) welding of the laps or seams. Also, double-sidedadhesive tapes, pre-applied adhesive with removable release paper,techniques may be utilized.)

As illustrated in FIGS. 7A-B, electrode leads 170 a and 170 b areconnected to the connection electrodes 430 and 431, and located near theedge of the module, e.g., the electrode or reference edge 134. FIG. 7Cshows the ends of the leads 170 a and 170 b having termination holes 700and 702 for series connection to wires or other connectors.

The wire or copper tape leads 170 a and 170 b are illustrated in furtherdetail in FIG. 8. Specifically, the leads 170 a and 170 b are connectedrespectively to the connection electrodes 430 and 431. The leads 170 aand 170 b extend perpendicular relative to the reference edge 134 of themodule 110 and over the membrane 140. In the example for series wiringshown in FIG. 2, the inter-module connection electrodes are connected inthis pattern with the exception of the inter-module connection betweenthe positive internal module electrode 175 b of module 115 and thenegative internal module electrode 176 a of module 116. In this case,the single electrical lead making the electrical circuit between 175 band 176 a (See FIG. 2A) extends across the reference edges 134 ofmodules 115 and 116. Thereafter, a wiring pattern similar to modules 110through 115 is completed for modules 116 through 121.

As illustrated in FIG. 9, the wire or internal module copper tape leads170 a and 170 b are connected in series with connectors 430 and 431 ofmodule 110. Specifically, the positive leads 170 b-174 b and negativeleads 171 a-175 a of modules 110-115 of the first group 210 areconnected in series by connectors 431-435, and the positive leads 176b-180 b and the negative leads 177 a-181 a of modules 117-121 areconnected in series by connectors 437-441 in the second group 212. Thenegative lead 175 b and the positive lead 175 b of modules 115 and 116are also connected by cross connector 436, thus completing the seriesconnection of the modules 110-121. Negative and positive “quick-connect”plugs 920 and 922 terminate the ends of leads 430 and 442 external tothe encapsulation membrane 490 and are readily available to connect tothe adjacent PV panel. Further, one or more of these series connectedpanels can be connected in parallel to an inverter. Other electricalconnections can also be used depending on the needs of a particularsystem, e.g., panels can be connected in parallel.

For example, a panel 200 having twelve modules 110 wired with thepreviously described series arrangement can provide 1536 Wstc and 571.2Voc output. This configuration also contains the wiring for the solarmodules 110 within the middle section 160, thereby simplifying theinstallation procedure. The output connections 430 a and 442 can then bedirected to a device which can process the solar energy and provideelectricity to the building structure or reverse metered into a powergrid. Further, a protective coating or layer 490 can be applied over thewire leads 170 a-181 a and 170 b-181 b for protection from inclementweather, animals, and other environment factors.

FIG. 10 shows an illustrative example of a cross-section of anintegrated photovoltaic component 100 or panel 200 that is attached to aroof or decking. In this example, an insulation layer 610 is laid onto adecking 1000 with, for example, an underlying insulation substrate 1010.A groove 1020 is cut within the insulation layer 610. An electricalconduit 1030 with the groove 1020 contains the cables 430 and 442 (seealso FIG. 9) connected by cable quick-connects 920 and 922 to home-runcable quick-connects 1050 and 1052 and extending therefrom as DC cablesto either electrical combiner box and/or inverter.

FIG. 11 generally illustrates a system 1100 for providing electricitygenerated by integrated photovoltaic roofing panels 200 of the presentinvention to a building structure. Generally, the panels 200 a and 200 bare manufactured and wired as previously described and illustrated. Theseries leads or electrodes from the modules are connected in parallel toan interface or current converter, such as an inverter 1110, forconverting the Direct Current (DC) electricity 1120 generated by thesolar panels 200 a and 200 b into Alternating Current (AC) electricity1130 at a certain voltage that can be utilized by the building structureor reverse metered into a power grid. One exemplary inverter 1110 thatcan be used is a photovoltaic static inverter, model no. BWT10240,Gridtec 10, available from Trace Technologies, Corp., Livermore Calif.These exemplary inverters 1110 are rated up to 600 volts DC input; 10kW, 120/240 or less, with single-phase output. Other inverters that canbe utilized include a string inverter or the Sunny Boy®2500 stringinverter, available from SMA America, Inc., 20830 Red Dog Road, GrassValley, Calif. A further exemplary inverter 1100 that can be used is theSine Wave Inverter, model no. RS400, available from Xantrex Technology,Inc., 5916 195th Street, Arlington, Wash. or a 20 kW Grid-Tiedphotovoltaic inverter, model no. PV-20208, also available from Xantrex.

Having described the integrated photovoltaic roofing component 100,panel 200, and system 1100, this specification now generally describesthe process for manufacturing a component 100 or panel 200 and theprocessing of the modules, membrane, adhesives and electrodes, and wireleads. Generally, the process involves positioning modules to belaminated, laminating the modules and flexible membrane together,sealing the edges of the laminated panel as necessary, and wiring thepanel.

Referring to FIG. 12, initially, the module surfaces are prepared oractivated in step 1200. Specifically, the bottom or Tedlar surfaces ofthe modules are activated by using, for example, a flame/coronatreatment system. A combination of flame and electrical discharge coronatreatment activate module surfaces which will receive a first hot-meltadhesive used to laminate the bottom surfaces of the modules to the topsurface of the flexible membrane sheet. The substrate of the module canbe cleaned and roughened to prepare for application of adhesive. Forexample, the module can travel across a flame (e.g., a 175 mm wideburner head (FTS 201) fueled by natural gas) at a rate of about 30 to 50meters per minute. The ends or sides of the modules are also exposed toa gas flame (or a corona in a combination gas/electric discharge flame)to activate the edges for application of a second hot-melt adhesive(edge adhesive). Module edges can be exposed to the flame at a rate ofabout 5 to 10 meters/minute.

In step 1205, the modules are loaded into position with, for example, asuction alignment system that loads the modules from a cassette intoposition onto a processing table or conveyor.

In step 1210, the modules are fed into a laminating machine, and a firstadhesive is applied to a substrate surface of the module. The adhesivecan metered or periodically applied to the bottom surface of the modulesif the modules are spaced apart from each other.

In step 1215, the flexible membrane is adhered to the modules. Themembrane can be placed in tension using a roller system for bettermating of the membrane and the hot-melt coated modules.

In step 1220, the module and the membrane are pressed together with asmoothing unit (calendar rollers) to mate or adhere the module andmembrane together. The lamination pressure is set either by gap orpressure up to, for example, about 300 N/cm for a total of 10,000 N overthe length of the calendar rollers.

In step 1225, the laminated product is permitted to set and cool.

In step 1230, a second adhesive, e.g., a HENKEL MM6240 adhesive, isapplied to the elongated, leading, and trailing edges of the panel as aprotective seal or pottant to protect the edges against weathering,moisture and other environmental pollutants that could damage themodules or cause the modules to be separated from the flexible membrane.Exemplary edge seals or pottants that can be utilized includeethylymethyl acrylate, poly-n-butyl-acrylate, EVA and elastomericpottants EPDM and polyurethane.

In step 1235, as necessary, additional seals and protective layers canbe applied to the panel. For example, a top protective layer can also beapplied to the modules for further protection. The cover layer providesfurther protection against environmental elements while beingtransparent or mostly transparent to sunlight (e.g., 90% transmission).Example outer layer materials that can be used include, but are notlimited to, Tedlar, a polyvinylfluoride (PVF), Kynar, a ploy-vinylidenefluoride, flexible plexiglass DR-61K and V811 from Rohn & Hass.

In step 1240, the panels are then electrically wired and cut to length.Series wiring of a panel is accomplished using flat copper tape which issoldered between adjacent modules. Soldering points are accessed bycutting circular holes through the bottom layer or roof side of theflexible membrane at the location of the module solder pads. A powerlead for each panel includes two “quick-connect” plugs which aresoldered to the positive and negative terminal leads of the series wiredmodules. The power leads are connected to other panels, to a combinerbox, to DC electrical devices or directly to a power inverter.

In step 1245, after the electrical lead soldering is completed, thecopper tape and power leads are encapsulated in PVC by hot-air welding,RF welding or hot-melt adhering an adequate strip of compatible flexiblemembrane to the central underside of the larger flexible membranethereby fully encapsulating and hermetically sealing and insulting theelectrical solder connections of the panel.

Having described various embodiments of the present invention, personsof ordinary skill in the art recognize that the integrated photovoltaiccomponent, panel and system of the present invention overcomes theshortcomings of conventional roofing materials, add-on solar modules,and known panels that also include solar modules to provide a moreeffective roofing solution. The present invention reduces the amount ofwiring and related hardware that is typically needed to connect solarmodules and connect solar modules to an inverter. The present inventionalso simplifies wiring since fewer connections are made, and the fewerconnections are made within a central area.

The foregoing description of embodiments of the present invention havebeen presented for the purposes of illustration and description. It isnot intended to be exhaustive or to limit the invention to the preciseforms disclosed. Many modifications and variations are possible in lightof the above teaching. For example, the integrated photovoltaic roofingpanel can be used with many different modules, flexible membranes,adhesives, and arrays of module configurations. Additionally, theintegrated photovoltaic component and panel can be used not only as aroofing component, but can also be applied to walls, canopies, tentstructures, and other building structures. Further, the integratedphotovoltaic roofing panel can be utilized with many different buildingstructures, including residential, commercial and industrial buildingstructures. It is intended that the scope of the invention be limitednot by this detailed description, but rather by the claims appendedhereto.

1. An integrated photovoltaic roofing component for attachment to aroofing surface, comprising: a flexible membrane having a top surfaceand a bottom surface, said bottom surface for application to the roofingsurface; a plurality of elongated photovoltaic modules arrangedside-by-side and attached to said top surface of said flexible membrane;and one or more electrical leads in electrical connection with saidmodules and located at adjacent ends of the modules.
 2. The component ofclaim 1, wherein said plurality of modules are attached to said topsurface of said flexible membrane with an adhesive.
 3. The component ofclaim 1, wherein said flexible membrane comprises a single-ply membrane.4. The component of claim 3, wherein said single-ply membrane is athermoplastic membrane sheet, an elastomeric membrane sheet, or areinforced bituminous membrane sheet.
 5. The component of claim 1,wherein each module includes a plurality of solar cells.
 6. Thecomponent of claim 5, wherein each module includes about 22 solar cells.7. The component of claim 1, wherein each module is flexible.
 8. Thecomponent of claim 1, wherein said one or more electrical leads areconnected in series.
 9. The component of claim 1, wherein said one ormore electrical leads of different modules are connected in series. 10.The component of claim 1, wherein said one or more electrical leadsextend through said flexible membrane.
 11. The component of claim 10,wherein said flexible membrane defines apertures through which said oneor more electrical leads extend.
 12. The component of claim 11, furthercomprising an insulative layer applied to said bottom surface of saidflexible membrane that covers said apertures defined by said flexiblemembrane.
 13. The component of claim 1, further comprising a seal alongan elongated edge between said flexible membrane and an elongatedphotovoltaic module.
 14. The component of claim 1, further comprising aseal along an end of said flexible membrane and an elongatedphotovoltaic module.
 15. The component of claim 1, further comprising aninsulative strip applied to said bottom surface of said flexiblemembrane.
 16. The component of claim 15, wherein said insulative stripis applied to the roofing surface.
 17. The component of claim 15,wherein said insulative strip encapsulates said one or more electricalleads.
 18. The component of claim 1, wherein said flexible membrane andsaid plurality of elongated photovoltaic modules attached to saidflexible membrane can be rolled upon themselves.
 19. The component ofclaim 1, wherein said one or more electrical leads are located in acentral area.
 20. The component of claim 1, wherein said plurality ofmodules are attached to a single sheet of flexible membrane.
 21. Thecomponent of claim 1, wherein a first group of two or more modules isarranged side-by-side and a second group of two or more modules isarranged side-by-side, wherein said first and second groups are alsoarranged end-to end so that said one or more electrical leads arelocated at adjacent ends of the modules of said first group and saidsecond group.
 22. The component of claim 21, wherein said one or moreelectrical leads of said first and second groups of modules are locatedin a central area. 23-47. (canceled)